Error proofing system for portable tools

ABSTRACT

A system for controlling and monitoring portable tools at a particular work cell remotely by R-F communication to provide error proofing of various parameters including that the correct tool is to be used at a work cell, the tool is properly calibrated for the operation to be performed, that it is being used a proper number of times per part being assembled or inspected, and that the tool has been calibrated within a selected service interval. The tools will be made actuable only by R-F communication with specific factory apparatus whereby theft of such portable tools will be inhibited.

This application is a broadening reissue of U.S. Pat. No. 6,845,279issued on Jan. 18, 2005 and also claims benefit under 35 U.S.C. §120 asa division of U.S. patent application Ser. No. 11/501,878 (the originalbroadening reissue application) filed on Aug. 9, 2006, which is areissue of U.S. Pat. No. 6,845,279 issued on Jan. 18, 2005.

FIELD OF THE INVENTION

The present invention relates to a system created to add assembly lineerror proofing and anti-theft features to existing portable tools. Thisinvention greatly enhances the capabilities of a wide variety of tooltypes, but, for purposes of simplicity, the tool type exemplified in thebody of this document shall be, by way of example, those used forinstalling threaded fasteners in assembling workpieces together.

BACKGROUND OF THE INVENTION

Many assembly lines require some way to determine that the tools beingused to perform assembly or operations requiring various parametersincluding predetermined magnitudes of torque, force, pressure, etc. at aparticular work cell and are the correct make and model that have beenproperly set up, configured, calibrated and maintained. They then mayrequire further error proofing to assure that the operations have beencorrectly performed by the technicians with the pre-approved tool thatis used the proper number of times per part being assembled orinspected. They may also require, over time, a constant verificationthat the tools have been properly maintained, calibrated, and/orcertified per a documented procedure or company quality policy. Forexample, a quality policy can place requirements for tool maintenanceand recalibration to be based on the number of times the tool is used(cycle count) and/or by elapsed time between maintenance andrecalibration. In traditional applications some such error proofing hasbeen done by non-portable tools which are directly connected by hardwired cables or hoses with hard wired cables to a work cell controllerwhereby they can derive electric, pneumatic or hydraulic power throughthese cables or hoses and various ones of those parameters noted beingmonitored via the hard wired cables. However, this cannot be done withportable tools such as battery operated tools or tools electricallyoperated by a simple cord connection to an electrical outlet. Thepresent invention provides a system for controlling and monitoringportable tools at a particular work cell by remote communication toprevent them from being used it they are not configured properly, notcalibrated properly, not the specified tool for this work cell, have anunacceptably high amount of use without being calibrated or serviced andhave some other unacceptable feature being monitored. The presentinvention further provides a means to disable a tool such that it cannotbe actuated when not in the presence of operatively related equipment atthe assembly factory thereby establishing anti-theft initiatives.

SUMMARY OF THE INVENTION

The present invention provides a system to enhance the use of tools thattoday have no way to provide substantial forms of error-proofing otherthan manual assurance. Through the addition of some intelligentelectronics in the tool and a supervisory computer at the work cell,this invention provides a means for providing error-proofing operationand anti-theft capabilities. In addition, the present invention providesmeans for providing other capabilities to be included in a variety ofequipment to facilitate monitoring the tools. Making some of the memoryinside the tool available to the end user shall allow the end user toinclude select ed information to be part of the data transferred betweenthe portable tool and the work cell controller that the end user deemspertinent for whatever additional information exchange needed to fulfillany additional tests, qualifications, or information exchange desired.This system and equipment enhances portable battery, electrical cord,hydraulic or compressed air powered tools to pro vide the requirementsfor them to be used in an error-proofed assembly line. In this regard,the system and equipment, for example, can assure that the correct toolmake, model number, and configuration is to be used at a work cell, thatthe tool being used is properly calibrated to a preselected targetvalue, that it is being cycled the proper number of times per part beingassembled, and that the tool has been serviced or calibrated withinrequired service intervals. Here such portable tools will be monitoredand controlled remotely by R-F (radio frequency) communication andwithout the need for hard wire cable connections for such monitoring andcontrol.

It should be understood, and as noted above, that a portable,non-battery electric tool can be utilized which is powered by anelectric power source at the work cell whereby only a typical, simpleelectric cord need to be provided for electrical connection. Thus suchtools would not have a hard wire cable connection for communication asnoted but could be monitored and controlled remotely by R-Fcommunication. In addition, a portable tool could be monitored by simplyhaving a battery operated, transceiver with data for tracking andmonitoring by R-F communication. It should also be understood thatpneumatic or hydraulic powered tools powered by hoses can be adapted toprovide monitoring at the work cell by R-F communication and without theneed for hard wire cable or other type of fixed wired transmissionconnection for monitoring. This could also facilitate maneuverability ofthe tool by the operator.

Therefore it is an object of the present invention to provide an errorproofing system for utilizing tools at work cells with the tools beingcontrolled and monitored remotely without the need for hard wire cableconnections.

It is another object of the present invention to provide a system forutilizing portable, self-powered tools at work cells with the toolsbeing controlled and monitored remotely for error proofing without theneed for hard wire cable connections.

It is another object of the present invention to provide a system forutilizing portable, self-powered battery or manually actuated tools atwork cells with the tools being controlled and monitored remotely byradio frequency (R-F) communication for error proofing and without theneed for hard wire cable connections.

It is another object of the present invention to provide a system forutilizing portable, self-powered battery or manually actuatedinstallation tools at work cells with the installation tools beingremotely monitored and controlled for error proofing by radio frequency(R-F) communication and without the need for hard wire cableconnections.

It is another object of the present invention to provide a system forutilizing portable, self-powered battery, electrically powered byelectric cord, or manually actuated tools at work cells with the toolsbeing remotely monitored and/or controlled for error proofing by radiofrequency (R-F) communication and without the need for hard wire cableconnections.

It is still another object of the present invention to provide a systemfor utilizing pneumatically or hydraulically actuated tools beingremotely monitored and/or controlled for error proofing by R-Fcommunication without the need for hard wire cable connections.

Further areas of applicability of the present invention will becomeapparent from the detailed description provided hereinafter. It shouldbe understood that the detailed description and specific examples, whileindicating the preferred embodiment of the invention with numerousspecific features, are intended for purposes of illustration only andare not intended to limit the scope of the invention nor itsapplicability of various combinations of specific features to otherapplications.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will become more fully understood from thedetailed description and the accompanying drawings, wherein:

FIG. 1 is a block diagram illustrating one form of the system of thepresent invention for error proof monitoring of a portable installationtool being used to install threaded fasteners including a toolmonitor-controller located within the portable installation tool, a workcell supervisor located at a particular work cell at which the tool isto be used, a preliminary set-up station typically at the facility thatsubsequently installs the monitoring and control electronics on the basetool and at which certain information relating to the tool is initiallyfed into the tool monitor-controller, a calibration station at theassembly factory at which the torque to be applied by the tool insetting a fastener at the assembly factory is set and recorded in thetool monitor-controller, and a portable audit device at the assemblyfactory by which an operator can audit certain information on portabletools located at various work cells and other locations; it also showsthe system in relation to a factory wide supervisor at the assemblyfactory;

FIG. 2 is a block diagram showing a portion of the system in which thetool monitor-controller is operable with the preliminary set up stationat the facility that installs the monitoring and control electronics andthe calibration station at the assembly factory;

FIG. 3 is a block diagram showing a portion of the system in which theinstallation tool is located for operation at a work cell and isoperable, remotely by communication with the work cell supervisor andcan be selectively remotely, monitored by the portable audit device whenit is out of the range of the work cell supervisor and at the same timethe work cell supervisor can be selectively monitored by the portableaudit device;

FIG. 4 is a block diagram of various components of the toolmonitor-controller and as operable with the preliminary set up station;

FIG. 5 is a block diagram of a component of the preliminary set upstation as operable with a component of the tool monitor-controller;

FIG. 6 is a block diagram of components of the calibration station andas operable with the tool monitor-controller;

FIG. 7 is a block diagram of components of the work cell supervisor asoperable with the tool monitor-controller in the work cell in which itis located; and also shows it communicable with the factory widesupervisor and a work cell transfer line;

FIG. 8 is a general pictorial diagram depicting a specific form of aportable, self-powered fastening tool with a tool monitor-controller ata work cell the operation of which is being monitored by a work cellsupervisor;

FIG. 9 is a general block diagram showing the working relationshipbetween the tool monitor-controller and various elements of the tool topermit monitoring of the installation tool and its fastening operations;

FIG. 10 is a general pictorial and block diagram showing a relationshipbetween the work cell supervisor and a portable tool; and

FIG. 11 is a schematic diagram of the circuitry of the toolmonitor-controller for a fastening tool for monitoring by a relatedsystem.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The following description of the preferred embodiment(s) is merelyexemplary in nature and is in no way intended to limit the invention,its application, or uses.

The system has a number of different interacting components. These aregenerally shown in block diagram form in FIGS. 1-7.

Looking now to FIG. 1, the portable self-powered installation tool 10 isprovided with a tool monitor-controller 12, which, as will be seen,provides the necessary information for monitoring the tool 10 for thedesired error-proofing operation. In this regard FIG. 1, generally showsthe interconnection between the installation tool 10 and variouscomponents of the system which include a work cell supervisor (WCS) 16at a particular work cell 14, a preliminary set up station 18, acalibration station 20 and a portable audit device 22 (PAD). In one formof the system, the work cell supervisor 16 and portable audit device 22can be connected to a factory wide supervisor 23 for purposes to beseen.

The installation tool 10 can be set to be used at a particular work cell14 to install fasteners to secure workpieces together. The operation ofthe tool 10 is remotely monitored and controlled at the work cell 14 bythe work cell supervisor 16 in a manner to be seen. In this regard, asseen in FIG. 1, the remote communication between the toolmonitor-controller 12 and work cell supervisor 16 is by radio frequency(R-F).

However, prior to locating the tool 10 in the work cell 14 at theassembly factory, it is first located at a preliminary set up station18. See FIGS. 2 and 5 Here, as will be seen, basic information about thetool 10 will be placed into the tool monitor-controller 12 by a set upPC 34 at the preliminary set up station 18 which is typically done atthe location where the electronics are added to the base tool aftercompletion of its manufacture. This could be at the facility whichmanufactured the base tool or at some other facility. It should beunderstood that the designation PC refers to a “personal computer”and/or a “portable computer”. As will be seen certain of the informationinitially put into the tool monitor-controller 12 by the preliminary setup station 18 will not be permitted to be changed by the end user at theassembly factory but certain other information will be permitted to bemodified, updated or initially placed therein.

Next, at the assembly factory site of the end user the portableinstallation tool 10 must be calibrated to provide the desired magnitudeof torque for its use to install fasteners at a particular work cell 14.In this regard, as will be seen, the tool 10 typically will have thecapability to provide torque over a significant range of magnitudes forthe same or different applications at work cells 14. In this regard, byway of example, the portable installation tool 10 can be a torque typetool for installing threaded fasteners and of a type such as a nutrunner for securing a nut to a bolt at a particular torque or a screwdriver for installing a threaded bolt or screw at a particular torque.

At the calibration station 20 the torque magnitude of the tool 10 willbe set by a technician to the desired level for a particular operationat a particular work cell 14. The adjustment of the tool 10 by theservice technician will be monitored and measured by the calibrationstation 20. See FIGS. 2 and 6. Once the proper magnitude has been setand verified, the calibration station 20 will then transmit thatcalibration information via an R-F link to a tool memory 30 in the toolmonitor-controller 12 in the installation tool 10 for later monitoringby the work cell supervisor 16. As will be seen, in one form of theinvention the tool memory 30 is a flash memory which is a part of a tooltransceiver to be described. See FIG. 6. Here, the calibration station20 will be routinely at a location remote from the work cell 14. Thecalibration station 20 preferably will use commercially availablecalibration devices that are certified to the appropriate national orinternational standards requirements (i.e. National Bureau ofStandards).

The present system also provides a portable audit device (PAD) 22 whichcan be carried by a roving quality inspector or tool repair technicianand used to audit various information in the tool monitor-controller 12.See FIGS. 1 and 3. This can be done at the work cell 14 withoutinterruption to normal assembly operations by the PAD 22 communicatingvia a hard line directly to the work cell supervisor 16 withoutdisrupting the R-F based communications between the tool 10 and the workcell supervisor 16. It is possible for the PAD 22 to communicatedirectly to the tool monitor-controller 12 of the tool 10 via an R-Flink where the PAD 22 is built from a device that can support the R-Flink directly, and an R-F linkage is not operational at that timebetween the work cell supervisor 16 and the tool monitor-controller 12.In this regard, the tool monitor-controller 12 will not permit R-Fcommunication with the PAD 22 if the tool monitor-controller 12 is inR-F communication with the work cell supervisor 16. The PAD 22 can bemanufactured from a number of portable computing devices similar to onessuch as a laptop computer, personal digital assistant, or a customembedded controller based system specially designed by one skilled inthe art. It should be understood, that the PAD 22 is not critical to theoverall system but in one form of the invention can be provided at theassembly factory for separate, selective auditing.

Looking now to FIG. 8, a typical portable, self-powered tool 10 isgenerally shown at a work cell 14 in preparation for fastening togethera pair of workpieces 24 and 26. In order to be sure that the tool 10 isthe correct one for properly installing the particular type offasteners, it is provided with numerous items of data accessible by thework cell supervisor 16 located at that work cell 14.

In this regard the tool monitor-controller 12 in the tool 10 is providedwith significant information and data which is stored and includes theinformation critical to being actuated for operation at the work cell14. This information is made available for monitoring by the work cellsupervisor 16. Thus in one form of the invention the toolmonitor-controller 12 can be provided with a tool memory 30 in which theinformation and data, items 1-24, (listed below) are stored. This listin no way limits the capabilities nor intent of this invention and isintended to be only an exemplary list of parameters that can beselectively revised or updated and further enhanced with softwarecomponent modifications.

It should be understood, that most or all of the items 1-24 may beinitially programmed into the tool memory 30 by the preliminary set upstation 18 at the facility where the electronics is installed. Each itemwill have its own identifiable memory location. However, the end usercan be provided with similar apparatus with a limited set up andrevision software. In one form, this type of software would be locatedat the calibration station 20 and allow the service technician access tocertain parameters using a special password access and to otherparameters not requiring a special password.

The following is an exemplary list of parameters:

The following is an exemplary list of parameters:

1. Tool Type—This is typically defined as a coded type plus manufacturercode. Tool Type could be one for Fastening, various Dimensionalchecking, Pressure checking, Force measurement and the like. A specificexample of this code would be FB for Fastening, Bosch, a tool made byBosch Tool Corporation, for fastening threaded fasteners. This is set bythe preliminary set up station 18 at the facility where the electronicsare installed and is not field changeable.

2. Tool Model Number—This is entered to reflect the tool manufacturer'smodel number in the format routinely displayed on the outer markings ofthe tool. This is set by the preliminary set up station 18 where theelectronics are initially installed or can be changed in the field byselected, certified technicians using password protected features of thecalibration station 20 when a change has been made to the mechanics ofthe tool that alter its applicability to a particular work cell or alterthe fundamental operation of a tool (new gear ratio, addition of specialend effectors, etc.)

3. Tool Serial Number—This is entered to reflect the tool manufacturer'sserial number routinely displayed in the format seen on the outermarkings of the tool. This is set by the preliminary set up station 18at the facility where the electronics are installed and is not field orend user changeable.

4. Tool Build Date—This is the date that the electronics with R-F linkenhancements for providing error proofing were installed in the basetool but is not the date the base tool was manufactured. This is set bythe preliminary set up station 18 where the electronics is initiallyinstalled and is not field changeable.

5. PCB Serial Number (printed circuit board)— This is the serial numberof the printed circuit board used to build the tool monitor-controller12. This is set by the preliminary set up station 18 at the facilitywhere the electronics is initially installed or can be changed in thefield by selected, certified technicians using the password protectedfeatures of the calibration station 20 when the module with a toolmonitor-controller 12 is replaced.

6. PCB Revision (printed circuit board)— This is the revision date ofthe printed circuit board used to build the tool monitor-controller 12.This is set by the preliminary set up station 18 at the facility wherethe electronics was installed or can be changed in the field at theassembly factory by selected certified technicians using the passwordprotected features of the calibration station 20 when a toolmonitor-controller 12 is replaced.

7. Tool Monitor-Controller Software Revision—This reflects the revisionof the software programmed into the memory 30 of the toolmonitor-controller 12. This can be set by the preliminary set up station18 at the facility where the electronics was installed or changed in thefield by selected, certified technicians using the password protectedfeatures of the calibration station 20 when the software in the toolmonitor-controller 12 is reprogrammed or replaced.

8. Total Tool Cycle Count—As a tool 10 is used and executes “good”cycles the tool monitor-controller 12 reports good cycle information tothe work cell supervisor 16. For a torque tool, a “good” cycle is whenthe desired magnitude of installation torque is attained in setting afastener. Because in some forms of the invention the amount ofprogramming space is highly limited in the tool monitor-controller 12and in the memory 30, the software to keep track of the number of cyclesa tool 10 has been run is executed in the work cell supervisor 16.Because, in some instances, it is the nature of the tool memory 30 to belimited in the number of times it can be successfully written into, inone case, the total tool cycle count is incremented only after 100 goodcycles have been run. After 100 good cycles have been performed, thework cell supervisor 16 writes a new (incremented by 100) total cyclecount into the memory 30 on the tool monitor-controller 12. This countis set at zero by the preliminary set up station 18 at the facilitywhere the electronics is initially installed and automaticallyincremented after each 100 cycles through the normal operation andinteraction of the tool monitor-controller 12 and the work cellsupervisor 16. This 100 cycle count cannot be reset at the customer siteand can only be changed at the facility where the electronics wasinstalled.

9. Cycle Count At Last Service Interval—This is set initially at zero bythe preliminary set up station 18 when the electronics is initiallyinstalled and is automatically reset using the calibration station 20when a tool is serviced and recalibrated by certified technicians. Whena tool is serviced, the calibration station 20 will read the total toolcycle count and copy its present value into the cycle count at lastservice interval automatically. It will also revise the 15. Date of LastCalibration to “today's” date.

10. Service Interval Cycles—This sets the maximum number of cyclesallowed to be run on a tool between service intervals. This is initiallyset at an appropriate number, i.e. for example 100,000 cycles, by thepreliminary set up station 18. This can then be reset by the calibrationstation 20. A tool is shut down by the work cell supervisor 16 if thetotal tool cycle count is greater than or equal to the tool's cyclecount at last service interval plus the pre-set service interval cycles.In one form of the invention, an alarm output will be generated by thework cell supervisor 16 if the total tool cycle count is greater than orequal to the tool's cycle count at last service interval plus 80% of thepre-set service interval cycles. This creates an alarm at 80% of theservice interval to assure plenty of time to re-certify the tool orprovide a replacement tool to avoid or minimize assembly line down time.The facility where the electronics is installed will place this defaultvalue into this parameter via the preliminary set up station 18, but theservice technician can change it at any time through the calibrationstation software 40 at the calibration station 20.

11. Date Of Last Service—This is automatically entered by thecalibration station 20 when a tool is re-calibrated after servicing. Itwill also revise 9. Cycle Count at Last Service, 13. Cycle Count At LastCalibration, and 15. Date of Last Calibration.

12. Service Interval Days—This sets the maximum number of calendar daysa tool is allowed to be run between servicing and is originally set atthe preliminary set up station 18 at an appropriate number, for example100 days. A tool is shut down by the work cell supervisor 16 if thepresent date is greater than or equal to the tool's date of last serviceplus the pre-set service interval days. In one form of the invention analarm output will be generated by the work cell supervisor 16 if thepresent date is greater than or equal to the tool's date of last serviceplus 80% of the pre-set service interval days. This creates an alarm at80% of the pre-set service interval days to assure plenty of time tore-certify the tool or provide a replacement tool to avoid or minimizeassembly line down time. The preliminary set up station 18 willinitially place this default value into this parameter, but the servicetechnician can change this default number at any time through thecalibration station software 40.

13. Cycle Count At Last Calibration—This is set at zero at the facilitywhere the electronics is installed and automatically set when a tool iscalibrated by certified technicians using the calibration station 20.When a tool is calibrated, the calibration station 20 will read thetotal tool cycle count and record its present value into the cycle countat last calibration automatically. It will also reset 15. Date of LastCalibration.

14. Calibration Interval Cycles—This sets the maximum number of cycles atool is allowed to be run between calibrations. A tool is shut down bythe work cell supervisor 16 if the total tool cycle count is greaterthan or equal to the tool's cycle count at last calibration plus thepre-set calibration interval cycles. In one form of the invention, analarm output will be generated by the work cell supervisor 16 if thetotal tool cycle count is greater than or equal to the cycle count atlast calibration plus 80% of the pre-set calibration interval cycles.This creates an alarm at 80% of the allowable cycle counts betweencalibrations to assure plenty of time to re-certify the tool or providea replacement tool to avoid or minimize assembly line down time. Thefacility where the electronics is installed will initially place adefault value into this parameter by the preliminary set up station 18,but the service technician can change it at any time through thecalibration station software 40.

15. Date Of Last Calibration—This is set at the facility where theelectronics is installed by the preliminary set up station 18 to thetool build date and automatically reset at the assembly factory when atool is calibrated by certified technicians using the calibrationstation 20.

16. Calibration Interval Days—This sets the maximum number of calendardays a tool is allowed to be run between calibrations. A tool is shutdown by the work cell supervisor 16, which determines the elapsed days,if the present date is greater than or equal to the tool's date of lastcalibration plus the pre-set calibration interval days. In one form ofthe invention an alarm output will be generated by the work cellsupervisor 16 if the present date is greater than or equal to the tool'sdate of last calibration plus 80% of the pre-set calibration intervaldays. This creates an alarm at 80% of the pre-set calibration intervaldays to assure plenty of time to re-certify the tool or provide areplacement tool to avoid or minimize assembly line down time. Thefacility where the electronics is installed will initially place adefault value into this parameter, but the service technician can changeit at any time through the calibration station software 40.

17. Customer Field 1—This memory location is open for customer use.These data fields are set at the facility where the electronics isinstalled to null characters by the preliminary set up station 18, butthe customer can insert information or change them at the assemblyfactory by using the calibration station 20.

18. Customer Field 2—see Customer Field 1.

19. Customer Field 3—see Customer Field 1.

20. Tool Maximum Capacity (torque, dimension, pressure, force, etc) inengineering units. This is set at facility where the electronics isinstalled by the preliminary set up station 18 or changed in the fieldat the assembly factory by certified technicians using the passwordprotected features of the calibration station 20 when a change has beenmade to the mechanics of the tool that alter its applicability to aparticular work cell 14 or alter the fundamental operation of a tool(new gear ratio, addition of special end effectors, etc.).

21. Engineering Units (Lb-Ft, Inches, PSI, Lbs, Etc.) This is set at thefacility where the electronics is installed by the preliminary set upstation 18 or changed in the field at the assembly factory by certifiedtechnicians using the calibration station 20 and the calibration stationsoftware 40.

22. Tool Minimum (Torque, Dimension, Pressure, Force, Etc.) This is setthe facility where the electronics is installed by the preliminary setup station 18 or changed in the field at the assembly factory bycertified technicians using the password protected features of thecalibration station 20 when a change has been made to the mechanics ofthe tool that alter its applicability to a particular work cell or alterthe fundamental operation of a tool (new gear ratio, addition of specialend effectors, etc.).

23. Spare—This is an open information site in the tool memory 30accessible by the calibration station 20 at the assembly factory to putin whatever information the end user desires monitoring, such as otherrebuild dates, etc.; it should be understood that a number of other openmemory locations could be provided for selected use by the end user.

24. Tool Setting (torque, dimension, pressure, force, etc). This isgenerated by the calibration station 20 and is typically the calculatedaverage of 10 cycles. This is set at the facility where the electronicsis installed by the preliminary set up station 18 or changed in thefield at the assembly factory by technicians using the calibrationstation 20 when an adjustment has been made to the average capability ofthe tool (e.g. adjustment to the torque clutch, etc.). The servicetechnician can change it at any time through the calibration stationsoftware 40.

The following chart provides a brief summary of the list of items 1-24discussed above.

Values And Data Entered into the Tool Memory 30 by the PreliminarySet-up Station 18 When Shipped to the Customer Value Set Into the ToolMemory 30 Item Parameter Name When Shipped *1 Tool Type Coded Tool Typeplus Manufacturer's Code  2 Tool Model Number Model number of base toolas it appears on the tool *3 Tool Serial Number Serial number of basetool as it appears on the tool *4 Tool Build Data The date the tool hadthe electronics installed. Useful for warranty liability  5 PCB SerialNumber (printed circuit The serial number of board) the ToolMonitor-Controller 12 printed circuit board  6 PCB Revision (printedcircuit board) The revision number of the Tool Monitor-Controller 12printed circuit board  7 Tool Monitor-Controller Software The revisionnumber of revision the Tool Monitor-Controller software installed *8Total Tool Cycle Count Zero  9 Cycle Count At Last Service Interval Zero10 Service Interval Cycles 100,000 11 Date Of Last Service The date thetool had the electronics installed 12 Service Interval Days 100 13 CycleCount At Last Calibration Zero 14 Calibration Interval Cycles 10,000 15Date Of Last Calibration The date the tool had the electronics installed16 Calibration Interval Days 1 17 Customer Field 1 Blank 18 CustomerField 2 Blank 19 Customer Field 3 Blank 20 Tool Max. Capacity (torque,Per Manufacturer's dimension, pressure, force, etc Specification 21Engineering Units (Lb-Ft, inches, PSI, Tool Specific Lbs, etc.) 22 ToolMinimum (torque, dimension, Per Manufacturer's pressure, force, etc).Specification 23 Spare Blank 24 Tool Setting (torque, dimension, 20% ofTool pressure, force, etc). Maximum Capacity *Identifies thoseparameters that are settable only by the Preliminary Set-up Station 18.

It should be noted that the data listed for certain of the monitoringparameters can be changed at the discretion of the end user, for examplesuch as 10. Service Interval Cycles, 12. Service Interval Days, 14.Calibration Interval Cycles and 16. Calibration Interval Days.

The Customer Fields 1-3 permit the end user at the assembly factory toput any type of information desired into the tool memory 30. Forexample, they could use it to specify what section or work cell of anassembly factory the tool 10 is allowed to be used at, the number oftimes the tool 10 had to be serviced during its life, the owners assetnumber, where the tool 10 was bought, etc. This information will beavailable at each work cell 14 to allow the end user to write softwareto perform any type of test, data logging, or asset (tool) trackingprogram they wish.

Thus the work cell supervisor 16 can then view or monitor all of theabove items stored in the tool memory 30. The work cell supervisor 16will be programmed to select from this data listed to qualify aparticular tool as allowed to operate. In addition, since the work cellsupervisor 16 is linked to the factory wide supervisor 23 all of thedata stored in the tools being used at work cells 14 in the assemblyfactory can be made available to the factory wide supervisor 23. Thus,through this link, supervisory or maintenance people can perform anaudit on the condition and location of all the portable tools locatedand active within this network. The embodiments of this specificationonly provide, by way of example, the mechanisms for making certain,selected data available to the factory wide supervisor 23 and makes noattempt at defining the other numerous ways that this data could bemodified and could be accessed and used.

As noted the installation tool 10 can be one of generally standarddesign such as a portable, battery operated torque tool. Here, in orderto correctly monitor the magnitude of torque as applied to a fastener,the tool 10 will have a (torque) measurement sensor 60. In this regardthe magnitude of torque could be sensed by a torque transducer builtinto the tool and monitored to determine the magnitude of torque appliedto each fastener. On the other hand some torque tools are provided witha mechanical sensor having a clutch which is adapted to be moved suchthat when the preset magnitude of torque is attained it will be movedsufficiently to open a switch whereby rotation of the motor is stopped.One such tool is manufactured by Bosch Tool Corporation¹. The clutchincludes a shut-off ring connected to a micro-switch, and a clutchspring and tension adjuster assembly. The clutch spring exerts aresilient bias against the shut-off ring. As torque on the fastenerincreases, the shut-off ring is moved against that resilient bias. Whenthe tool reaches the pre-set magnitude of torque, the shut-off ring ismoved against the bias of the clutch spring to a position opening themicro-switch whereby rotation of the motor is stopped. The magnitude ofshut-off torque can be selectively set by adjustment of the tensionadjuster which is accessible to the service technician equipped with anyspecial tooling necessary to change the amount of resilient bias neededto be overcome to open the micro-switch. Now the condition of themicro-switch is sensed and provides the signal of correct magnitude ofapplied torque when it is opened.

¹ BOSCH® is the registered trademark of Robert Bosch GmbH.

The specific details of such tools with torque transducers as sensors orwith torque responsive clutches are known in the art and do notconstitute a part of the present invention and thus have been omittedfor simplicity and brevity. For example, the use of a torque limitingclutch for limiting the torque to selected magnitudes and to act as aswitch is noted in U.S. Pat. No. 6,662,882 issued Dec. 16, 2003 toHanson for Power Nut Runner With Torque Responsive Power Shut Off andU.S. Pat. No. 3,792,632 issued Feb. 19, 1974 to Pinkerton for Tool ForTorquing And Crimping Fasteners.

As noted the portable installation tool 10 has the toolmonitor-controller 12 located therein. The various components of thetool monitor-controller 12 are shown in FIG. 4. There it can be seenthat the monitor-controller 12 has a tool embedded controller 32 whichis actuable to control the operation of the tool 10.

The tool embedded controller 32 receives the signal from the (torque)measurement sensor 60 each time a fastener is set at the preselectedmagnitude of torque. The embedded controller 32 is also connected to thetool memory 30 and has access to the information stored therein. Thetool monitor-controller 12 has a tool R-F transceiver 28 by which thetool 10 can communicate wirelessly by radio frequency with the work cellsupervisor 16, the calibration station 20 and the portable audit device22. See FIG. 1.

Since, for this particular example of implementation, the R-F link istypified as a Bluetooth™. R-F link, the tool memory 30 can be attainedby using a 4 Mbit Flash memory similar to an SST39VF4 or equivalent, anduse the Persistent Store User Definable Data values as defined byCambridge Silicon Radio re the CSR chip and Bluetooth™ protocol(commercially available) as a transport mechanism to get the data fromthe tool memory 30 to become available at the work cell supervisor 16.The use of the Bluetooth™ protocol is the protocol used for thisexample. Bluetooth R-F modules and transceivers are commonly used andare commercially available. But it should be understood that othercommercially available R-F transceivers and modules are commonly used.For example alternatives to Bluetooth™ such as 802.11, WiFi, or Zigbeecould be used to perform the same R-F function as that described herein.Therefore, the tool R-F transceiver 28 can be selected from a number ofcommercially available ones.

As noted, before the portable installation tool 10 is used it is firstprogrammed at the preliminary set up station 18 at the facility wherethe electronics is installed, then calibrated at the assembly factory atthe customer site by the calibration station 20.

Thus the installation tool 10 is taken to the calibration station 20 forsetting the tool 10 to provide the desired magnitude of torque. See FIG.6.

Looking now to FIG. 6, the calibration station 20 includes a calibrationdevice 36, a calibration PC 38 with computer software 40, and acalibration R-F transceiver 42.

When the tool 10 is being calibrated there are two paths forcommunication into and out of the calibration PC 38. The calibration PC38 uses the first bi-directional link to drive the R-F link to the toolmonitor-controller 12 via the calibration R-F transceiver 42 and thetool R-F transceiver 28. The implementation of these communication portscould be done in many ways, but in one form will mainly be configured asa plug-in card for a PC (PCMCIA, Compact Flash, etc), or a custom designfor a single board computer design. The calibration PC 38 has a second(cabled) serial link to the calibration device 36. When the tool 10 isbrought into proximity to the calibration R-F transceiver 42 the twoautomatically locate each other via the R-F link and begin a dialogue.The computer software 40 in the calibration PC 38 will identify all ofthe parameters inside the tool 10 and first see if the two have evercommunicated before, or if this is a new tool to the assembly factory.If they have not, the software 40 in the PC 38 will start a new recordfor this particular tool. This record will become part of the data in adatabase, such as an Access or Excel database, that records all of thecalibration and service data for this tool 10 through its life. Thisdata also becomes valuable for asset tracking because it can provide arich history of the location of and use of a particular tool. Thecalibration computer software 40 will automatically create a new entryand a database record without the operator ever picking up a pencil ormanually logging calibration data. This software operates this way tomake it easy to introduce a new tool into a plant. Just bringing thetool into proximity of the calibration station 20 will automaticallycreate a log of this new tool's presence in the assembly factory andstore all of the information associated with that tool. Because it isprobable that in very large assembly plants there may be more than onecalibration station 20, the information available in these tools isintended to be stored at a central computer called a factory widesupervisor 23 typically located on a factory-wide communicationsnetwork. If the calibration station 20 recognizes this tool as onepreviously communicated with, it will not create a new tool entry, butappend data to the existing records. However, a calibration station 20different from the one originally accessed by the tool 10 can secure thebackground information from the factory wide supervisor 23.

When the tool 10 runs a fastener element on the calibration device 36,the calibration device 36 automatically sends this data across thecabled serial line into the calibration PC 38. The PC 38 displays thetorque values to the operator, gives the operator an opportunity toreject the torque value of a particular cycle (if there was a problemwith that particular cycle), then averages the torque magnitude ofmultiple cycles. In one form, after the portable tool 10 runsapproximately 10 cycles, the average torque of these cycles as noted bythe PC 38, if at the proper magnitude, is written into the tool memory30 by the operator via the R-F link between the tool transceiver 28 andthe calibration transceiver 42. After this happens, the tool 10 is nowcarrying inside its memory 30 the information that identifies themagnitude of the average torque it produces to set a fastener, and thisinformation is included in all future R-F dialogue. If the magnitude ofthis torque average is unacceptable, the service technician can adjustthe clutch or other control apparatus in the tool 10 to raise or lowerthe average torque to a value closer to the desired target and run thetest again until the tool 10 is set to create an average torquemagnitude that is within desired tolerances.

A special enhanced version of the calibration station 20 can be used formajor tool repair or reconfiguration. The enhanced version of softwarecan be called “the tool repair station” just for differentiationpurposes for this disclosure. Such a tool repair station can have all ofthe capabilities of the calibration station 20, but through the use ofpasswords and privileged access to supplemental software that will beincluded in the calibration station software 40 will allow the certifiedservice technician to gain access to altering some of the parametersstored in the tool memory 30 of the tool 10. The tool repair station canfacilitate repairs or reconfigurations done at the user's site at theassembly factory or an outside source other than the tool factory byspecified trained technicians. Only through entering the proper passcodes will such a selected repair technician be able to gain access toall of the parameters that need to be changed when modifications aremade to the tool that affect its capabilities, e.g. change to a gearratio, addition of a gear stage that would effect direction of rotation,a revised set of software programmed into the tool 10, etc. Thecalibration station 20 will be linked to the factory wide supervisor 23to provide the data necessary to keep a current and central file on alltools located within the assembly factory. If the assembly factorypersonnel want to start repairing these tools, then routinely this willbe done by a trained or certified repair technician capable of repairingthese tools. The following chart identifies those tool parameters thatcan be changed by the calibration station 20, and those parametersaccessible solely through password enabling as would be used after atool repair. In the chart an “N” indicates that the parameter can bechanged without entering a password, a “Y” indicates that the parametercan be changed at the calibration station only if the proper passwordhas been entered (as would be done after a tool repair).

Parameters Alterable by the Calibration Station & by the PasswordEnabled Calibration Station N = No, Y = Yes Calibration Tool ItemParameter Name Station Repair 2 Tool Model Number N Y 5 PCB SerialNumber (printed circuit board) N Y 6 PCB Revision (printed circuitboard) N Y 7 Tool Monitor-Controller 12 N Y Software revision 9 CycleCount At Last Service Interval Y Y 10 Service Interval Cycles Y Y 11Date Of Last Service Y Y 12 Service Interval Days Y Y 13 Cycle Count AtLast Calibration Y Y 14 Calibration Interval Cycles Y Y 15 Date Of LastCalibration Y Y 16 Calibration Interval Days Y Y 17 Customer Field 1 Y Y18 Customer Field 2 Y Y 19 Customer Field 3 Y Y 20 Tool Max. Capacity(torque, dimension, N Y pressure, force, etc. 21 Engineering Units(Lb-Ft, inches, Y Y PSI, Lbs, etc.) 22 Tool Minimum Capacity (torque, NY dimension, pressure, force, etc). 23 Spare Y Y 24 Tool Setting(torque, dimension, Y Y pressure, force, etc). Note: Parameters 1, 3, 4& 8 are not listed because they are non-field-changeable.

Now the installation tool 10 is set for setting fasteners to anappropriate torque at the selected work cell 14. When the electronics inthe portable installation tool 10 is installed, the tool embeddedcontroller 32 is set to maintain the tool 10 deactuated. Thus the tool10 will not operate without the proper R-F actuating signal being givento the embedded controller 32, by the calibration station 20, the workcell supervisor 16 or the portable audit device 22. Typically at thework cell 14 the portable tool 10 is queried by the work cell supervisor16. If the portable tool 10 is configured properly, and has not beenused for periods that violate the company's quality policies for timeand/or cycles between calibration or service periods, the tool 10 willbe enabled to run by the work cell supervisor 16. This assures that atool 10 will not operate without an R-F master station within its R-Frange and will only operate if a pre-defined set of qualifications aremet.

Looking now to FIG. 7, the work cell supervisor 16 has a supervisorplatform 50 with a supervisor PC 52. It can also be a single boardcomputer. The supervisor software 54 in the supervisor PC 52 of the workcell supervisor 16 will constantly be searching for intelligent tools tolink up via the R-F linkage. When the portable tool 10 is brought intothe work cell 14 in proximity to the R-F range of the work cellsupervisor 16 the two automatically find each other via the R-F linkbetween the tool R-F transceiver 28 and the work cell supervisor R-Ftransceiver 46. They will then begin a dialogue very similar to thedialogue between the calibration station 20 and the portable tool 10.The supervisor software 54 in the work cell supervisor 16 will identifyall of the parameters inside the portable tool 10 and first see if thetool 10 has been set to a torque setting that is acceptable for thisparticular work cell 14. If the tool 10 has the correct torque setting,the work cell supervisor 16 will then look at the acceptable limits forcycles and days between calibrations and all other criteria deemedcritical for that particular work cell 14. To keep the quality of theparts being assembled high, plants will frequently have the maximumnumber of cycles that are allowed to be run between checking theportable tool 10 for torque accuracy set relatively low. As noted in thelist of data in the tool memory 30, the tool 10 will store inside thetool memory 30 the number of cycles that were run when the tool 10 waslast calibrated and last serviced and the date when the tool 10 was lastcalibrated and last serviced. In addition it has the maximum number ofcycles and maximum number of days allowable between last calibration andservicing. This data will be monitored by the work cell supervisor 16.If the number of cycles or number of days has not been exceeded and allother criteria have been met, the work cell supervisor 16 will issue thecommand across the R-F link to enable the tool 10 to start operating.After the tool 10 has been enabled, the work cell supervisor 16 willconstantly be monitoring the cycle count and elapsed days forcalibration and service requirements and set the appropriate outputs toflag quality technicians for their attention. Maintenance and qualitypeople will be made aware of this need for corrective action via serialmessages to the factory wide supervisor 23 and visual indications at thework cell supervisor 16 and/or digital outputs from the work cellsupervisor 16 indicating that there is pending or immediate need forattention.

It is common in many factories to have a centrally located factory widesupervisor 23 in which information from various work cells 14 can bemonitored by quality systems supervisors. In the present invention, thework cell supervisor 16 is communicable with a factory wide supervisor23 via a factory wide local area network. See FIGS. 1 and 7. Here thework cell supervisor platform 50 is linked to the factory widesupervisor 23 on a cabled Ethernet or an Ethernet like factory widecommunications network 55. Thus initially the work cell supervisor 16will communicate the serial number of each tool 10 in the work cell 14to the factory wide supervisor 23 via factory wide communicationsnetwork 55 whereby the location of the tools such as tool 10 can betracked and calibration and servicing requirements audited and alsotracked for asset assessment.

The work cell supervisor 16 writes new data into the tool 10 via the R-Flink for “8. Total tool cycle count,” and will calculate the cycle countsince last service and the cycle count since last calibration based onthe cycle count recorded when the tool 10 was last calibrated orserviced (“9. Cycle count at last service interval” and (“13. Cyclecount at last calibration”). As noted since the tool memory 30 insidethe tool 10 in some instances can be written only a limited number oftimes, the work cell supervisor 16 will be programmed to write new cyclecount data only every 100 cycles or other selected number. In addition,at recalibration, the calibration station 20 writes new data into thetool memory 30 via the R-F link for 13. Cycle Count At Last Calibrationand 15. Date Of Last Calibration.

In addition, after service with recalibration, the Calibration Station20 will write new data into the tool memory 30 via the R-F link for 9.Cycle Count At Last Service Interval and 11. Date Of Last Service, 13.Cycle Count At Last Calibration and 15. Date Of Last Calibration.

As noted, in some embodiments the work cell supervisor 16 provides adigital output signal at a programmable percentage (e.g. 80%) of themaximum allowable cycles or elapsed time between calibrations andbetween last service. This signal or flag is also serially transmittedto the factory wide supervisor 23. This permits advanced arrangement forrecalibration or service or for a replacement tool to be prepared foruse at the work cell 14 with minimal down time of the assembly line.

After these checks have been made and the tool 10 becomes operational, acommunication packet between the tool 10 and work cell supervisor 16occurs after each fastening cycle has been successfully completed, i.e.proper torque applied to each fastener. From an assembly line point ofview an assembly of particular workpieces will require the correcttorque applied for a predetermined number of fastening cycles. The workcell supervisor platform 50 of the work cell supervisor 16 will beprogrammed to know just how many cycles are required per part beingassembled for each tool 10 and provide an interface to an assembly linecontrol via a work cell transfer line 56 to know when the pre-set numberof fastening cycles has been properly performed so the parts beingassembled can be released out of this work cell 14 for furtherprocessing.

As indicated above, in some situations it would be desirable for aqualified technician to audit various portable installation tools 10 atdifferent work cells 14 or other locations. As noted this can be done bythe portable audit device 22 which can be carried by a roving inspectoror tool service technician. As can be seen in FIG. 3, the portable auditdevice 22 has a PAD PC 58 with a PAD R-F transceiver 62 by which theaudit device 22 can communicate with the tool monitor-controller 12 ofthe tool 10 via the tool R-F transceiver 28 if out of a work cell 14, orto the work cell supervisor 16 by cable. Although it is possible toconfigure the portable audit device 22 in many forms it could likelyappear as a Personal Digital Assistant (PDA). Also, as noted, theprovision of a PAD 22 is not necessary for the routine error proofingdescribed.

As previously noted, the R-F transceivers can be selected fromcommercially available ones and as such are provided with antennas forR-F transmission and reception. However, in one form of the presentinvention each of the R-F transceivers 28, 42, 46 and 62 were of thesame basic construction and were Bluetooth™ modules currently availableas Windigo Bluetooth™ BTM0202C2XX-P.² In this regard, each Bluetooth™module has a unique node address, in that every node has a guaranteedunique address identifier. Thus no two tools 10, two work cellsupervisors 16, two calibration stations 20 or two portable auditdevices 22 will ever repeat or respond to the same node address. Thisinformation is included inside the Bluetooth™ modules as purchased.

² Bluetooth is the trademark of Bluetooth SIG Inc.: these Bluetoothmodules are from Windigo Systems, Inc.

When the tool 10 is initially built, it will not operate without beinggiven permission to run either at the calibration station 20, by thework cell supervisor 16 at a work cell 14 or by a portable audit device22. However, the tool 10 will be deactivated when it is removed from therange of the work cell supervisor 16, calibration station 20 or portableaudit device 22. This assures that the tool 10 will not operate withoutan R-F master station within its R-F range. Since the tool 10 cannot beactivated without a proper R-F signal, such as from a work cellsupervisor 16, there will be little or no incentive for theft. This isalso true for the portable tool activated by wire connectable to a powersource since that type of tool also will not be activated without theproper R-F signal.

It should be noted, however, that with any portable tool 10 in which theelectronics is battery operated, a simple mechanism, such as a manualswitch or timer, could be provided to disconnect the battery or place itinto a sleep mode whereby the electronics for providing the R-F signalwould be deactivated resulting in increased battery life. In thisregard, with portable tools having batteries with the R-F signalcontinuously on, a security device at the assembly factory exits couldbe used to detect if a portable tool 10 is being removed from thefactory without permission.

Since the R-F signals from the R-F transceiver are active all of thetime the units are powered up, they are always open to communicate withother Bluetooth™ based R-F transceivers. These devices have beendesigned to communicate specifically to other Bluetooth™ based devicesdue to the open interoperability, noise immunity, and international R-Ffrequency standardization. There are a number of embedded codes such asthe node addresses and group classifications that can be used to limitthe types of devices that will be permitted to communicate together. Itshould be noted, that the R-F transceivers require minimal energywhereby the batteries can have a long life without recharging.

The R-F link via the Bluetooth™ module as noted is available in twoclasses. Class 1 can transmit and receive up to 100 ft. (200 ft. dia.circle) while a class 2 can transmit and receive up to 30 ft. (60 ft.dia. circle). In one form of the invention the range was limited toclass 2 to minimize possible interference between adjacent work cellsupervisors 16.

The following discussion defines various connections between theapparatus and circuitry as shown in FIGS. 9-11. It should be understoodthat not all of the connections between the elements are specificallydiscussed since, as noted below, some of the elements are commerciallyavailable and well known to those skilled in the art. Thus all of suchdetails are not provided for purposes of brevity and simplicity.

FIG. 11 illustrates the electrical circuits designed to interface withthe switches and lights of a power tool as well as provide an R-F pathfor getting this information between the portable tool 10 and the workcell supervisor 16, portable audit device 22 and the calibration station20. The Bluetooth™ module U2 requires 3.3 VDC regulated power which isgenerated by the base module, has I/O (input-output) lines, serial portsfor communications, serial port for programming the tool memory 30, andan external antenna. All of the support for the R-F module has beenplaced on a second printed circuit module called the base module. Thetool embedded controller 32 on the Bluetooth™ module U2 includes aprocessor chip which is a chip manufactured by Cambridge Silicon Radioand is programmable by SPP Master Software.

Regulated power for the R-F module is generated by a voltage regulatorU1. The tool's battery power is brought through a 12 pin connector Conn1into the voltage regulator U1. The voltage regulator U1 regulates thewidely varying battery voltage to a very constant 3.3 VDC. This canallow the R-F module U2 to operate inside tools that have a wide varietyof battery voltage levels. The regulator U1 will be used to eliminatethe affects of battery voltage drops during high current loads andtypical battery discharge from normal use. Regulator U1, located on thebase module, is connected to the Windigo module U2 through one of the 34solder tabs located around the perimeter of the Windigo module U2 thatconnect the Windigo R-F module U2 to the circuitry of the base module.I/O (input-output) lines are brought to the base module through theconnector Conn1. These I/O lines interconnect to a variety of places, adetailed description of each follows.

These connections are listed in the order of connection to connectorConn1:

Pins 1 & 11—Ground. This is the negative terminal of the tool's batterypack. It is the ground used by all of the electronics inside the tool10.

Pin 2— W_ToolEnableln (Tool Enable)— This is the signal produced by theelectronics of the base module in the tool 10 that normally causes thetool 10 to operate. The application software executed by the CSR RISCprocessor takes the W_ToolEnableln signal as a request to run the tool10, but will not allow the tool 10 to operate unless a predetermined setof qualifications are met as determined by the WCS 16, calibrationstation 20, or PAD 22. These devices transmit an R-F packet into theWindigo U2 module that has a bit in it that is logically “Anded” withthe W_ToolEnableln, then converted into a physical output pointToolEnableOut. The base module effectively “intercepts” the Tool Enablecommand to take control of the tool 10. A pull-up resistor R7 to 3.3 VDCholds the logic level high and a transistor Q1 is used to pull thesignal to a logic “0” for the Windigo Module U2. On the Windigo moduleU2 this line is presented to the I/O lines of the Cambridge SiliconRadio chip which is the tool embedded controller 32, which includes thestate of this bit into the data transmitted via the R-F communicationlink.

Pin 3— nClutch (Good Cycle)— This is a signal generated by theclutch-switch that is actuated only after the tool 10 has produced thedesired amount of torque, indicating a good cycle has been run. Theclutch is a device that is based on a torque induced cam-over actionthat generates linear motion as the clutch is engaged. This linearmotion is detected by a mechanical switch and this signal is presentedinto the base module. Because the switch provides a closure to GND(ground), the only required voltage level translation is a pull-upresistor R5 to 3.3 VDC. On the Windigo module U2 this line is presentedto the I/O lines of the Cambridge Silicon Radio chip 32 (the toolembedded controller 32), which includes the state of this bit into thedata transmitted via the R-F communication link.

Pin 4— W_RevCycle (Rev Cycle)— This is a signal produced at the tool'strigger switch when the switch is placed in the Reverse mode and thetrigger is pulled. It is sent back to the work cell supervisor 16 when areverse cycle has been run for whatever the end user wishes to use itfor, (e.g. user may want to monitor the number of times a day anoperator backed out a bolt). A pull-up resistor R11 to 3.3 VDC holds thelogic level high and a transistor Q3 is used to pull the signal to alogic “0” for the Windigo Module U2. On the Windigo module U2 this lineis presented to the I/O lines of the Cambridge Silicon Radio chip 32(embedded controller 32), which includes the state of this bit into thedata transmitted via the R-F communication link.

Pin 5—SPI_MISO—This is one of the wired serial lines used to program theFLASH memory 30 on the Windigo module. It stands for SynchronousPeripheral Interface—Master In, Slave Out. It passes straight throughthe base module and is used during the programming of the software andpreset of the variables used in the Bluetooth packet protocol. Becausethis is all logic level, no voltage translation is required.

Pin 6 _SPI_CSB—This is one of the wired SPI serial lines used to programthe FLASH memory 30 on the Windigo module U2. It stands for SynchronousPeripheral Interface—Chip Select Bit. It passes straight through thebase module and is used during the programming of the software andpre-set of the variables used in the Bluetooth packet protocol. Becausethis is all logic level, no voltage translation is required.

Pin 7 _SPI_CL—This is one of the wired SPI serial lines used to programthe FLASH memory 30 on the Windigo module U2. It stands for SynchronousPeripheral Interface—Clock. It passes straight through the base moduleand is used during the programming of the software and preset of thevariables used in the Bluetooth packet protocol. Because this is alllogic level, no voltage translation is required.

Pin 8 _SPI_MOSI—This is one of the wired SPI serial lines used toprogram the FLASH memory 30 on the Windigo module U2. It stands forSynchronous Peripheral Interface—Master In Out, Slave Out In. It passesstraight through the base module and is used during the programming ofthe software and pre-set of the variables used in the Bluetooth packetprotocol. Because this is all logic level, no voltage translation isrequired.

Pin 9—W_ForCycle (Forward Cycle)— This is a signal produced at thetool's trigger switch when the switch is placed in the Forward mode andthe trigger is pulled. It just means that the tool 10 is running in atightening mode. It is used by the application software executed by theCSR RISC processor 32 in conjunction with the clutch input to determinewhen a forward running cycle has been run that has caused the clutch toactuate the micro-switch. This conditioned signal constitutes anindication that a successfully run tightening cycle has been executed.This event is transmitted back to the WCS 16 to be used as a cyclecounter. A pull-up resistor R9 to 3.3 VDC holds the logic level high anda transistor 02 is used to pull the signal to a logic “0” for theWindigo Module U2. On the Windigo module U2 this line is presented tothe I/O lines of the Cambridge Silicon Radio chip 32, which includes thestate of this bit into the data transmitted via the R-F communicationlink.

Pin 10— ToolEnableOut (Tool Enable). This signal is the processedversion of ToolEnableln. If the tool 10 has been enabled by the WCS 16,calibration station 20 or PAD 22 the tool 10 will be enabled by thisoutput allowing power to flow through the trigger switch when it ispulled. This signal goes to the logic level control of the power driversinside the trigger switch, (see FIG. 9 Tool Enable). Because this is alogic level, no voltage translation is required. This line will go to 0VDC to disable the tool 10.

Pin 12—+VBatt. This is the positive terminal of the battery. The batteryvoltage will vary across the various models of portable tools, and willalso fluctuate substantially during heavy loading of the electric motorinside the tool 10. This unregulated battery voltage goes to the voltageregulator U1 on the base module; then regulated DC voltage goes into theWindigo module U2.

The following lists the connections to connector CONN2 and theinteraction of other elements:

Serial Port for Communications—The CSR/Windigo module supports a serialport for communication. Although the portable tool does not use thesesignals, they are useful when a Bluetooth link needs to be establishedin the work cell supervisor 16 when it is based on an IBM PC. Conn 2pins 1-4 make up the lines required for a serial port. Conn2 pin 1 isthe serial Receive (RX) of the R-F module U2; pin 2 is the Request toSend (RTS); pin 3 is the serial Transmit (TX) of the R-F module U2, andpin 4 is the signal that it is Clear to Send (CTS) messages. These linesare used in standard serial communications data links and thus are wellknown in the art and thus the details thereof are omitted for purposesof simplicity and brevity.

The Synchronous Peripheral Interface (SPI)— This is a wired serial portof a high speed logic level port typically used for communicationsbetween a processor and its peripheral devices. In this application theSPI port is used to download executable source code and some of thevariables called persistent store into the FLASH memory 30 on theWindigo Module U2. A special programming device made by CSR called aCasira is used to generate the SPI interface. The signals involved aredefined previously in Conn1 pins 5-8.

FIG. 9 shows other various interconnected elements of the system.

1. Bluetooth Antenna—Because of the infinite number of packagingconstraints, Windigo has chosen to provide the R-F signal, but not theR-F antenna. This gives module users a wide variety of possibilities forantenna type and mounting locations. For the purposes of the presentportable tool 10 a very small surface mounted antenna has been chosen.This antenna ANT1 is manufactured by GigaAnt corp. and is soldereddirectly to the base printed circuit module.

2. Yellow and Green LED—There are two light emitting diodes, a YellowLED1 and a Green LED2 located on the base module. They have beenprogrammed to indicate the status of the portable tool 10 regarding itsability to be used. The Yellow LED1 is used to indicate that there isradio frequency communication between the tool 10 and some other device.It is programmed to flash while the tool 10 is looking to connect tosome other R-F based unit, then go to a solid lit condition once an R-Flink has been established with any other Bluetooth enabled device. Ifthe tool is removed from the work cell 14 the LED1 will flash. The GreenLED2 provides an indication that the tool 10 has been enabled and iscapable of running a cycle. In this regard, the circuitry of the tool 10will activate the Green LED2 if the voltage level provided by thebattery is correct for operating the tool 10. If it is not at thecorrect level, the LED2 will not be lit providing an alert signal to theoperator and a signal to the work cell supervisor 16 that the tool 10cannot be actuated by R-F communication.

Looking to FIG. 10, circuits for the work cell supervisor 16 are shown.

The Inputs and Outputs of the Work Cell Supervisor 16 include: ClearCycle Count—This input resets the Cycle Count to zero.

The Cycle Count is the number of “good” cycles performed on a particularpart being assembled (e.g. car) at the work cell 14. The work cellsupervisor 16 will keep track of the number of times a tool 10 has beenrun to good torque and (optionally) disable the tool 10 when it hasreached the predetermined number of cycles for that assembly. If, forexample a dashboard were being fastened into a car and there were twelvefasteners required to secure it in place, the work cell supervisor 16will keep the running count of good fastening operations and when twelvefasteners are applied the work cell supervisor 16 will (optionally)disable the tool 10. This becomes a checks and balances for the assemblytechnician. If the assembly technician is attempting to tightenfasteners on the next scheduled car before the assembly line controlequipment acknowledges the old car cleared out and the new car to be inposition, the tool 10 will be maintained disabled. This prevents “walkahead” where an assembly line technician using a portable tool startsworking on a new car before it is logged in at the designated work cellarea 14.

In an enhanced and optional mode, the work cell supervisor 16 willenable the tool monitor-controller 12 to permit the tool 10 to run apre-determined number of good cycles, then must make the tool 10inoperable. This is done in instances where the integrity of the R-Flink is diminished due to temporary radio frequency interference or aneed to temporarily operate a tool 10 over distances greater than theR-F link will allow. As in the example above where elements are to befastened into a car and a selected number of fasteners are required tosecure it in place, the work cell supervisor 16 will enable the toolmonitor-controller 12 to keep the running count of good fastening cyclesand when the selected number of fasteners have been applied, to disablethe tool 10 and, when R-F communication is re-established to then informthe work cell supervisor 16 that all of the required cycles have beenrun and to allow the work cell supervisor 16 to initiate the sameoutputs it would to the work cell transfer line 56 as it would duringnormal operation. This feature allows the tool 10 to leave the directcommunication with the R-F link only for a predetermined number ofcycles before the tool 10 is disabled by the tool monitor-controller 12.Typical examples of how this feature would be used are in applicationssuch as deep inside a trunk, glove box, or behind the instrument panelwhere it is possible to intermittently lose the R-F link. This allowsthe tool 10 to be run independently of the work cell supervisor 16 justlong enough without the direct contact with the R-F link to complete theassembly of a single car. When the assembly technician leaves the carand is walking to the next vehicle, the R-F link between the work cellsupervisor 16 and the tool monitor-controller 12 will becomereestablished and, if the correct number of good cycles are noted, thecounter will be reset in the tool 10 enabling the tool 10 to run theappropriate number of cycles required for the next vehicle.

Asserting the Clear Cycle Count—This will reset the cycle counter tozero and will re-enable the tool 10 to run if it had been previouslystopped because it had reached terminal Cycle Count. This input willtypically be generated by the operator at a small operator station witha momentary pushbutton switch.

Decrement Cycle Count—Assertion of this input will cause the cyclecounter to be decremented by one (unless the count is at zero). Thisinput can be used by a technician when the Cycle Counter is incrementedinaccurately, as in the case where an operator tightened the samefastener to an acceptable torque level twice (often called a doublehit). Another situation is where there is cross threading between thefastener elements but the acceptable torque level is still reached. Thisdecrement input will typically be generated by the operator at a smalloperator station with a momentary pushbutton switch to reduce the cyclecount.

Allow Tool to Run—Assertion of this input will cause the work cellsupervisor 16 to send permission for the tool 10 to run regardless ofany of the cycle count, cycles since calibration, torque calibration,etc. test results. This should be a highly secured input switch that isaccessible only by a special key. The purpose of this input is to allowthe tools to resort to their native state where human supervision is theonly check to assure the tools are operating correctly. This mode istypically used, for example, when building a prototype assembly. A tool10 is needed to be used for some function other than its normal purpose,the assembly line tracking logic is inoperable, or other unforeseencircumstances. The tool 10 will still not operate unless it is locatedinside the work cell 14 or near a PAD 22 or calibration station 20 whereit is receiving the Bluetooth R-F command to run.

Reset Cycle Count—Functionally the same as the Clear Cycle Count, butsourced from a different place. The assembly line operator needs apushbutton (Clear Cycle Count) to reset everything in the event theoperator somehow gets things out of synchronization, but in addition,when everything is running properly the operator should not have to doanything to maintain assembly line flow other than run thepre-prescribed assembly routine. The line tracking equipment should beset up to advance a new (car) into the work cell 14 and reset the cyclecounter by asserting the Reset Cycle Counter automatically. Thistypically comes from a programmable Logic Controller (PLC) that iscontrolling assembly line flow. When a new vehicle enters the work cell14, the line controlling PLC will assert the Reset Cycle Counter for abrief time; the cycle counter will be reset to zero, and the tool 10will be enabled to run.

Output Power—This is the voltage used to drive digital inputs andoutputs for the work cell supervisor 16. In some cases it is typically24 VDC.

Cycle Complete—This is a signal that indicates that a good fasteningcycle has just been completed. It is not often used in automatedassembly lines, but is available to drive an output (into a PLC), or anindicator light.

Part Complete—This output goes active when the required number of goodcycles have been performed on a particular part. This typically is wiredinto the assembly line controlling PLC so it can know when to advancethe assembly line. The Part Complete output from the work cellsupervisor 16 will typically trigger the assembly line controlling PLCto generate the Reset Cycle Count input into the work cell supervisor16.

Tool Operational—This output from the work cell supervisor 16 thatindicates the tool 10 is fully operational and capable of runningfastening cycles. A lack of this signal will most likely trigger arequirement for a service technician to determine what has caused thistool 10 to become non-operational. Typical causes for this signal to gofalse are: The tool 10 is not adjusted to the proper torque for thisapplication, the tool 10 has been run too many cycles and has not beencalibrated as required, the R-F link between the tool 10 and the workcell supervisor 16 is not operating, etc.

Tool Requires Attention—This output is a warning that a condition existsthat will immanently shut down a tool 10. This will occur when a tool 10has been run too many cycles without being re-certified.

It can be seen that the present system provides a wide variety ofmonitors and control features which can be selectively varied fornumerous applications. Thus the description of the invention is merelyexemplary in nature and, thus, variations that do not depart from thegist of the invention are intended to be within the scope of theinvention. Such variations are not to be regarded as a departure fromthe spirit and scope of the invention.

1. An error proofing system for portable tools comprising: a portable,electrically operated tool for applying torque to set a threadedfastener on a workpiece at a work cell, said tool having a toolmonitor-controller operable for controlling the operation of said tool,said tool being pre-set to provide an output torque of a desiredmagnitude, said tool monitor-controller having a radio frequency tooltransceiver for communication with selected devices, one of said devicesbeing a work cell supervisor located at the work cell to monitor andcontrol said tool, said work cell supervisor having a radio frequencysupervisor transceiver for communicating with said tool through saidtool transceiver when said tool is in the work cell, said tool having atorque sensor for sensing the magnitude of torque applied to eachthreaded fastener in installation and with the torque magnitude noted insaid tool monitor-controller, said tool providing a torque signal tosaid work cell supervisor by radio frequency communication between saidtool transceiver and said supervisor transceiver when the applied torqueof the desired magnitude is reached in setting the threaded fastenerwhereby the work cell supervisor can count the number of properinstallation torque cycles, said tool monitor-controller having presetinformation regarding the desired magnitude of setting torque on saidtool and other information as to certain parameters necessary for saidtool to be actuated, said work cell supervisor being preset as to thedesired magnitude of setting torque and other information necessary forsaid tool to be activated and if such information is correct said workcell supervisor will then provide a signal to said monitor-controller bycommunication between said tool transceiver and said supervisortransceiver to permit said tool to be activated for installing fastenersin the work cell but if the desired magnitude of setting torque is notcorrect or one of the other parameters is not correct then said toolwill not be activated by said work cell supervisor.
 2. The errorproofing system of claim 1 with said work cell supervisor having apreselected number of torque cycles of desired magnitude required to beproduced by the tool on the work piece at the work cell, said work cellsupervisor keeping count of the number of correct torque cycle signalsreceived from said tool monitor-controller of said tool, if the numberof correct torque cycle signals of desired magnitude is attained thensaid work cell supervisor will permit the workpiece to be transferredfrom the work cell, if the number is not attained then said work cellsupervisor will provide a signal whereby the workpiece can be checked.3. The error proofing system of claim 1 with said portable electricallyactuated tool being battery operated.
 4. The error proofing system ofclaim 1 with said portable electrically actuated tool being powered byconnection of an electric cord to a power source at the work cell andincluding a battery in the tool for energizing said monitor-controllerfor continuous radio frequency communication by said tool transceiverand with transceivers on other apparatus.
 5. The error proofing systemof claim 1 with said other parameters including information regardingpreselected intervals for recalibration.
 6. The error proofing system ofclaim 1 with said other parameters including information regardingpreselected intervals for servicing.
 7. The error proofing system ofclaim 1 with said other parameters including information regarding apreselected number of cycles of installed fasteners for recalibration.8. The error proofing system of claim 1 with said other parametersincluding information regarding preselected number of cycles ofinstalled fasteners for servicing.
 9. The error proofing system of claim1 with said other parameters including information regarding apreselected number of elapsed days for recalibration.
 10. The errorproofing system of claim 1 with said other parameters includinginformation regarding preselected number of elapsed days for servicing.11. The error proofing system of claim 1 with said devices including aportable audit device having a radio frequency transceiver forcommunicating with said tool through said tool transceiver formonitoring certain information in said tool monitor-controller.
 12. Theerror proofing system of claim 1 with said tool monitor-controllerhaving preset information as to certain parameters which cannot bechanged by the end user or in the field and includes at least one of thefollowing: tool type, tool serial number or tool build date.
 13. Theerror proofing system of claim 1 including a calibration station forcalibrating said tool to said desired magnitude of output torque andhaving a radio frequency calibration transceiver for communicating withsaid tool monitor-controller through said radio frequency tooltransceiver for providing said tool monitor-controller with said presetinformation regarding said magnitude of setting torque as set at saidcalibration station.
 14. The error proofing system of claim 1 with saidtool monitor-controller including a printed circuit board and softwareand including restricted access means requiring a preselected passwordfor changing information in said tool monitor-controller relating to oneor more of revision to said printed circuit board or circuit boardserial number, software revision, tool maximum capacity or tool minimumcapacity.
 15. The error proofing system of claim 1 including acalibration station for calibrating said tool to said desired magnitudeof output torque and having a radio frequency calibration transceiverfor communicating with said tool monitor-controller through said radiofrequency tool transceiver for providing said tool monitor-controllerwith said preset information regarding said magnitude of setting torqueas set at said calibration station, said tool monitor-controllerincluding a printed circuit board and software and with said calibrationstation including restricted access means requiring a preselectedpassword for changing information in said tool monitor-controllerrelating to one or more of revisions to said printed circuit board orcircuit board serial number, software revision, tool maximum capacity ortool minimum capacity.
 16. The error proofing system of claim 1 withsaid tool monitor-controller including at least one open memory locationto permit the end user to insert selected information in such memorylocation.
 17. The error proofing system of claim 1 with said work cellsupervisor having means selectively operable by an operator forresetting the recorded cycle count of the number of correct torquemagnitude to zero.
 18. The error proofing system of claim 1 with saidwork cell supervisor having means selectively operable by an operatorfor incrementally reducing the recorded cycle count of the number ofcycles of correct magnitude.
 19. The error proofing system of claim 1with said work cell supervisor including control means selectivelyactuable by an operator to permit said tool to be operated substantiallywithout restriction within said work cell but with said control meansincluding restricted access means to selectively limit access to saidcontrol means.
 20. The error proofing system of claim 1 with saiddevices including a portable audit device having a radio frequencytransceiver for communicating with said tool through said tooltransceiver for monitoring certain information in said toolmonitor-controller, such communication occurring outside of the range ofsaid supervisor transceiver.
 21. The error proofing system of claim 1with said other information in said tool monitor-controller as tocertain parameters including information as to the make and/or modelnumber of said tool, said work cell supervisor being preset as toinformation as to the desired make and/or model number of said tool tobe operable at the work cell and if such information from said toolmonitor-controller is not correct then said tool will not be actuated bysaid work cell supervisor.
 22. The error proofing system of claim 1 withsaid tool monitor-controller having a memory for numerous fieldsincluding total tool cycle count, data as to last service and lastcalibration, said work cell supervisor recording the total number ofcycles performed by said tool while in the work cell and periodicallyupdating the total tool cycle count in a memory of said toolmonitor-controller after a preselected number of cycles.
 23. The errorproofing system of claim 1 with said other parameters includinginformation regarding identification of said tool, information forperiodic servicing of said tool, and information for periodiccalibration of said tool.
 24. The error proofing system of claim 23 withsaid noted information being accessible by said work cell supervisor byradio frequency communication.
 25. The error proofing system of claim 23including a calibration station for calibrating said tool to saiddesired magnitude of output torque and having a radio frequencycalibration transceiver for communicating with said toolmonitor-controller through said radio frequency tool transceiver forproviding said tool monitor-controller with said preset informationregarding said magnitude of setting torque as set at said calibrationstation and with said noted information being accessible by saidcalibration station by radio frequency communication.
 26. An errorproofing system for portable tools comprising: a portable, electricallyoperated tool for applying torque to set a threaded fastener on aworkpiece at a work cell, said tool having a tool monitor-controlleroperable for controlling the operation of said tool, said tool beingpre-set to provide an output torque of a desired magnitude, said toolmonitor-controller having a radio frequency tool transceiver forcommunication, a work cell supervisor located at the work cell tomonitor and control said tool and having a radio frequency supervisortransceiver for communicating with said tool through said tooltransceiver when said tool is in the work cell, said tool having atorque sensor for sensing the magnitude of torque applied to eachthreaded fastener in installation and with the torque magnitude noted insaid tool monitor-controller, said tool providing a torque signal tosaid work cell supervisor by radio frequency communication between saidtool transceiver and said supervisor transceiver when the applied torqueof the desired magnitude is reached in setting the threaded fastenerwhereby the work cell supervisor can count the number of properinstallation torque cycles, said tool monitor-controller having presetinformation regarding the desired magnitude of setting torque on saidtool, said work cell supervisor being preset as to the desired magnitudeof setting torque for said tool to be activated and if such informationis correct said work cell supervisor will then provide a signal to saidmonitor-controller by communication between said tool transceiver andsaid supervisor transceiver to permit said tool to be activated forinstalling fasteners in the work cell but if the desired magnitude ofsetting torque is not correct then said tool will not be activated bysaid work cell supervisor.
 27. The error proofing system of claim 26with said work cell supervisor having a preselected number of torquecycles of desired magnitude required to be produced by the tool on thework piece at the work cell, said work cell supervisor keeping count ofthe number of correct torque cycle signals received from said toolmonitor-controller of said tool, if the number of correct torque cyclesignals of desired magnitude is attained then said work cell supervisorwill permit the workpiece to be transferred from the work cell, if thenumber is not attained then said work cell supervisor will provide asignal whereby the workpiece can be checked.
 28. The error proofingsystem of claim 26 with said portable electrically actuated tool beingbattery operated.
 29. The error proofing system of claim 26 with saidportable electrically actuated tool being powered by connection of anelectric cord to a power source at the work cell and including a batteryin the tool for energizing said monitor-controller for continuous radiofrequency communication by said tool transceiver with transceivers onother apparatus.
 30. The error proofing system of claim 26 with saidtool monitor-controller including information regarding preselectedintervals for recalibration, said work cell supervisor receiving suchinformation and providing a signal to alert for recalibration by or atthe selected interval.
 31. The error proofing system of claim 26 withsaid tool monitor-controller including information regarding preselectedintervals for servicing, said work cell supervisor receiving suchinformation and providing a signal to alert for servicing by or at theselected interval.
 32. The error proofing system of claim 26 with saidtool monitor-controller including information regarding a preselectednumber of cycles of installed fasteners for recalibration, said workcell supervisor receiving such information and providing a signal toalert for recalibration by or at the preselected number of cycles. 33.The error proofing system of claim 26 with said tool monitor-controllerincluding information regarding a preselected number of cycles ofinstalled fasteners for servicing, said work cell supervisor receivingsuch information and providing a signal to alert for servicing by or atthe preselected number of cycles.
 34. The error proofing system of claim26 with said tool monitor-controller including information regarding apreselected number of elapsed days for recalibration, said work cellsupervisor receiving such information and providing a signal to alertfor recalibration by or at the preselected number of elapsed days. 35.The error proofing system of claim 26 with said tool monitor-controllerincluding information regarding a preselected number of elapsed days forservicing, said work cell supervisor receiving such information andproviding a signal to alert for servicing by or at the preselectednumber of elapsed days.
 36. The error proofing system of claim 26 withsaid devices including a portable audit device having a radio frequencytransceiver for communicating with said tool through said tooltransceiver for monitoring certain information in said toolmonitor-controller, such communication occurring outside of the range ofsaid supervisor transceiver.
 37. The error proofing system of claim 26with said tool monitor-controller having preset conformation as to otherparameters including information regarding identification of said tool,information for periodic servicing of said tool, and information forperiodic calibration of said tool.
 38. The error proofing system ofclaim 37 with said noted information being accessible by said work cellsupervisor by radio frequency communication.
 39. The error proofingsystem of claim 37 including a calibration station for calibrating saidtool to said desired magnitude of output torque and having a radiofrequency calibration transceiver for communicating with said toolmonitor-controller through said radio frequency tool transceiver forproviding said tool monitor-controller with said preset informationregarding said magnitude of setting torque as set at said calibrationstation and with said noted information being accessible by saidcalibration station by radio frequency communication.
 40. An errorproofing system for portable tools comprising: a portable, electricallyoperated tool for applying torque to set a threaded fastener on aworkpiece at a work cell, said tool having a tool monitor-controlleroperable for controlling the operation of said tool, said tool beingpre-set to provide an output torque of a desired magnitude, said toolmonitor-controller having a radio frequency tool transceiver forcommunication, a work cell supervisor located at the work cell tomonitor and control said tool and having a radio frequency supervisortransceiver for communicating with said tool through said tooltransceiver when said tool is in the work cell, said tool having atorque sensor for sensing the magnitude of torque applied to eachthreaded fastener in installation and with the torque magnitude noted insaid tool monitor-controller, said tool monitor-controller having presetinformation regarding the desired magnitude of setting torque on saidtool, said work cell supervisor being preset as to the desired magnitudeof setting torque for said tool to be activated and if the magnitude ofsetting torque is correct said work cell supervisor will then provide asignal to said monitor-controller by communication between said tooltransceiver and said supervisor transceiver to permit said tool to beactivated for installing fasteners in the work cell but if the desiredmagnitude of setting torque is not correct then said tool will not beactivated by said work cell supervisor.
 41. The error proofing system ofclaim 40 with said portable tool being activated only when in the radiofrequency range of said work cell supervisor or other device having aradio frequency transceiver communicable with said radio frequency tooltransceiver to selectively provide a signal activating said portabletool, said portable tool being deactivated and not otherwise actuablewhen out of the range of said radio frequency transceivers of said workcell supervisor or other of said devices whereby theft of said portabletool is inhibited.
 42. The error proofing system of claim 41 with saidradio frequency of said tool being continuously actuated to provide theradio frequency signal whereby a monitor at the location of saidportable tool can detect the presence of said tool at exit areas wherebytheft of said portable tool is inhibited.
 43. An error proofing systemfor portable tools comprising: a portable tool for performing apreselected task on a workpiece at a work cell, said tool having a toolmonitor-controller operable for controlling the operation of said tool,said tool being pre-set to provide the task at a desired magnitude, saidtool monitor-controller having a radio frequency tool transceiver forcommunication with selected devices, one of said devices being a workcell supervisor located at the work cell to monitor and control saidtool, said work cell supervisor having a radio frequency supervisortransceiver for communicating with said tool through said tooltransceiver when said tool is in the work cell, said tool having asensor for sensing the magnitude of the task applied to the workpiece,said tool providing a task magnitude signal to said work cell supervisorby radio frequency communication between said tool transceiver and saidsupervisor transceiver when the applied task of the desired magnitude isreached whereby the work cell supervisor can monitor the operation ofsaid tool, said tool monitor-controller having preset informationregarding the desired magnitude of the setting of the task on said tooland other information as to certain parameters necessary for said toolto be actuated, said work cell supervisor being preset as to the desiredmagnitude of the task and other information necessary for said tool tobe activated and if such information is correct said work cellsupervisor will then provide a signal to said monitor-controller bycommunication between said tool transceiver and said supervisortransceiver to permit said tool to be activated to perform task in thework cell but if the desired magnitude of the task is not correct or oneof the other parameters is not correct then a signal will be generatedwhereby said tool should not be activated.
 44. An error proofing systemfor portable tools comprising: a portable, electrically operated toolfor applying torque to set a threaded fastener on a workpiece at a workcell, said tool having a tool monitor-controller operable forcontrolling the operation of said tool, said tool being pre-set toprovide an output torque of a desired magnitude, said toolmonitor-controller having a radio frequency tool transceiver forcommunication, a work cell supervisor located at the work cell tomonitor and control said tool and having a radio frequency supervisortransceiver for communicating with said tool through said tooltransceiver when said tool is in the work cell, said tool having atorque sensor for sensing the magnitude of torque applied to eachthreaded fastener in installation and with the torque magnitude noted insaid tool monitor-controller, said tool providing a torque signal tosaid work cell supervisor by radio frequency communication between saidtool transceiver and said supervisor transceiver when the applied torqueof the desired magnitude is reached in setting the threaded fastenerwhereby the work cell supervisor can count the number of properinstallation torque cycles, said tool monitor-controller having presetinformation regarding the desired magnitude of setting torque on saidtool, said work cell supervisor being preset as to the desired magnitudeof setting torque for said tool to be activated and if such informationis correct said work cell supervisor will then provide a signal to saidmonitor-controller by communication between said tool transceiver andsaid supervisor transceiver to permit said tool to be activated forinstalling fasteners in the work cell but if the desired magnitude ofsetting torque is not correct then said tool will not be activated bysaid work cell supervisor, said work cell supervisor capable ofactivating said tool by R-F communication with said toolmonitor-controller to permit said tool to be activated to installfasteners outside of the R-F range of said supervisor transceiver for apreselected interval.
 45. The error proofing system of claim 44 withsaid preselected interval when said tool is activated to installfasteners outside of the R-F range of said supervisor transceiver beinga preselected number of cycles of applied torque of the desiredmagnitude as counted by said tool monitor-controller.
 46. A methodcomprising: providing a work cell supervisor with a radio frequencysupervisor transceiver, the radio frequency supervisor transceiverdefining a communication zone; providing a portable tool that can beactuated by a user for performing a task, the portable tool having atool monitor-controller with a radio frequency tool transceiver, thetool monitor-controller being in a first condition that inhibits useractuation of the portable tool; placing the portable tool within thecommunication zone to permit the radio frequency supervisor transceiverand the radio frequency tool transceiver to communicate, the work cellsupervisor transmitting an activation signal, the radio frequency tooltransceiver receiving the activation signal and the toolmonitor-controller responsively operating in a second condition thatpermits user actuation of the portable tool for performing an operationthat consists of a predetermined quantity (n) of the tasks; interruptingcommunication between the radio frequency tool transceiver and the radiofrequency supervisor transceiver before the operation is complete;operating the tool while communication between the radio frequency tooltransceiver and the radio frequency supervisor transceiver isinterrupted to complete the predetermined quantity (n) of tasks andthereafter operating the tool monitor-controller in the first conditionto prevent initiation of a task in excess of the predetermined quantity(n) of tasks without at least first re-establishing communicationbetween the radio frequency supervisor transceiver and the radiofrequency tool transceiver.
 47. The method of claim 46, wherein theportable tool is electrically-powered.
 48. The method of claim 47,wherein the portable tool is battery-powered.
 49. The method of claim46, wherein the portable tool is pneumatically-powered.
 50. The methodof claim 46, wherein the portable tool is hydraulically-powered.
 51. Themethod of claim 46, wherein the portable tool provides a rotary output.52. The method of claim 46, wherein the work cell supervisor transmitsthe activation signal after confirming that a data set transmitted fromthe tool monitor-controller meets a set of predetermined criteria. 53.The method of claim 52, wherein the data set includes a tool settingvalue that is indicative of a magnitude of the output of the portabletool when the tool performs the task.
 54. The method of claim 53,further comprising inhibiting actuation of the portable tool if aparameter other than the tool setting value is outside a predeterminedlimit.
 55. The method of claim 54, wherein the parameter includes aninterval for recalibration of the portable tool.
 56. The method of claim55, wherein the interval for recalibration is based on a quantity (t) oftasks.
 57. The method of claim 55, wherein the interval forrecalibration is based on a quantity (d) of days.
 58. The method ofclaim 54, wherein the parameter includes an interval for servicing theportable tool.
 59. The method of claim 58, wherein the interval forservicing is based on a quantity (t) of tasks.
 60. The method of claim58, wherein the interval for servicing is based on a quantity (d) ofdays.
 61. The method of claim 46, wherein interrupting communicationbetween the radio frequency tool transceiver and the radio frequencysupervisor transceiver includes removing the portable tool from thecommunication zone.
 62. The method of claim 46, further comprisingtransmitting a message from the radio frequency tool transceiver to theradio frequency supervisor transceiver to acknowledge that at least aportion of the operation has been successfully completed.
 63. The methodof claim 62, wherein the message is transmitted after completion of eachof the quantity (n) tasks.
 64. The method of claim 46, wherein the workcell supervisor communicates the quantity (n) to the toolmonitor-controller.
 65. A method comprising: providing a portable toolthat can be actuated by a user for performing a task, the portable toolhaving a tool monitor-controller with a radio frequency tooltransceiver, the tool monitor-controller being in a first condition thatinhibits user actuation of the portable tool; initiating radio frequencycommunication between a calibration station and the portable tool andcausing the tool monitor-controller to operate in a second conditionthat permits user actuation of the portable tool; determining a toolsetting value that is indicative of a magnitude of an output of theportable tool when the portable tool performs a predetermined task; andtransmitting the tool setting value from the calibration station to thetool monitor-controller; wherein the portable power tool is operated toproduce the output but is not employed to determine the tool settingvalue.
 66. The method of claim 65, further comprising adjusting theportable tool to change the magnitude of the output of the portable toolwhen the portable tool performs the predetermined task.
 67. The methodof claim 65, wherein initiating radio frequency communication betweenthe calibration station and the portable tool comprises placing theportable tool within a predetermined distance from the calibrationstation.
 68. A method comprising: providing a work cell supervisor witha radio frequency supervisor transceiver, the radio frequency supervisortransceiver defining a communication zone; providing a portable toolthat can be actuated by a user for performing a task, the portable toolhaving a tool monitor-controller with a radio frequency tooltransceiver, the tool monitor-controller being in a first condition thatdoes not provide validation that the task has been performed by theportable tool; placing the portable tool within the communication zoneto permit the radio frequency supervisor transceiver and the radiofrequency tool transceiver to communicate, the work cell supervisortransmitting an activation signal, the radio frequency tool transceiverreceiving the activation signal; and operating the toolmonitor-controller in a second condition that permits the toolmonitor-controller to transmit a message to validate that the task hasbeen performed by the portable tool.